P4.41 Hydrogen reacts with iron oxide (Fe₂O3) to produce metallic iron (Fe), with water vapor as a byproduct. 100% conversion of Fe₂O3 is achieved, and the metallic iron is easily separated from the hydrogen-water vapor mixture. The water is condensed, and the hydrogen is recycled. The hydrogen source is contaminated with 1 mol % CO. The recycle:fresh feed ratio is 4:1, and the maximum allowable CO in the gas fed to the reactor is 2.5 mol %. Draw a flow diagram, and complete a DOF analysis. Then calculate the single-pass and overall conversion of H₂ as well as all process flows, for a production rate of 1 ton/day metallic iron. (Hint: Consider changing basis to the gas feed.)

Solved: P4.41 Hydrogen reacts with iron oxide (Fe₂O3) to produce metallic iron

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p4 41 hydrogen reacts with iron oxide fe o3 to produce metallic iron f

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P4.41 Hydrogen reacts with iron oxide (Fe₂O3) to produce metallic iron (Fe), with water vapor as a byproduct. 100% conversion of Fe₂O3 is achieved, and the metallic iron is easily separated from the hydrogen-water vapor mixture. The water is condensed, and the hydrogen is recycled. The hydrogen source is contaminated